EP1967354B1 - Procédé de moulage continu de matériel composite ayant une épaisseur sélectionnable par paliers - Google Patents

Procédé de moulage continu de matériel composite ayant une épaisseur sélectionnable par paliers Download PDF

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Publication number
EP1967354B1
EP1967354B1 EP07405292A EP07405292A EP1967354B1 EP 1967354 B1 EP1967354 B1 EP 1967354B1 EP 07405292 A EP07405292 A EP 07405292A EP 07405292 A EP07405292 A EP 07405292A EP 1967354 B1 EP1967354 B1 EP 1967354B1
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EP
European Patent Office
Prior art keywords
prepreg
composite material
peel ply
molding
thickness
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Not-in-force
Application number
EP07405292A
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German (de)
English (en)
Other versions
EP1967354A1 (fr
Inventor
Masatoshi c/o Jamco Corporation Aijima
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Jamco Corp
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Jamco Corp
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Filing date
Publication date
Application filed by Jamco Corp filed Critical Jamco Corp
Publication of EP1967354A1 publication Critical patent/EP1967354A1/fr
Application granted granted Critical
Publication of EP1967354B1 publication Critical patent/EP1967354B1/fr
Not-in-force legal-status Critical Current
Anticipated expiration legal-status Critical

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C33/00—Moulds or cores; Details thereof or accessories therefor
    • B29C33/56—Coatings, e.g. enameled or galvanised; Releasing, lubricating or separating agents
    • B29C33/68—Release sheets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • B29C70/34—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation
    • B29C70/345—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation using matched moulds

Definitions

  • the present invention relates to a method for continuously molding a composite material by use of prepreg obtained by impregnating a thermosetting resin into a carbon fibre or the like.
  • the composite material has uniform sectional thickness at the time of continuous molding, and the prepreg peel ply and/or an unnecessary portion of the prepreg are peeled and removed after curing so that the thickness of the composite material varies stepwise.
  • Patent Document 1 Japanese Patent Laid-Open Publication No. 1-4315
  • Patent Document 2 Japanese Patent Laid-Open Publication No. 2-102029
  • Patent Document 3 Japanese Patent Laid-Open Publication No. 2001-191418
  • Patent Documents 1 to 3 disclose molding of a member having a uniform sectional shape and uniform sectional thickness, but do not disclose molding of a member with its sectional shape and thickness varied.
  • the document WO 2008/019894 which is an Art. 54(3) EPC document, discloses a production method for a workpiece composed of a support means, like a film, onto which a main material composed of a pre-impregnated fibre semi-finished product is applied in order to form two blank-mould areas which are pressure-bonded to one another. In a subsequent step, the film provided on the surface of the workpiece is removed.
  • the production process is preferably carried out as a continuous production process.
  • This document also relates to a fibre-composite component in the form of a profile with a profile cross section which varies over its length.
  • the present invention is directed to providing a method for continuously molding a composite material.
  • the composite material has a uniform sectional shape and thickness at the time of continuous molding, and the prepreg peel ply and/or an unnecessary portion of the prepreg are peeled and removed after curing so that the thickness of the composite material varies stepwise.
  • a method for continuously molding prepreg according to the present invention includes a method for continuously molding a composite material as defined in claim 1.
  • the prepreg peel ply has a substantially equal thickness to that of the prepreg and contains substantially the same resin as that in the prepreg.
  • the prepreg and the prepreg peel ply are arranged in the longitudinal or width direction of the molding material.
  • a molding material has uniform thickness and can thus be cured in one molding step by a continuous molding device, and the prepreg peel ply and/or an unnecessary portion of the prepreg are peeled and removed after curing, it is possible to mold a composite material having stepwise sectional thickness.
  • a molding method it is possible to mold a homogeneous member without defects such as fibre disturbance and voids.
  • the composite material has no interface of a bonding portion or an additionally laminated portion. It is therefore possible to produce a member having high static strength and high fatigue strength.
  • a thickness varying step may be set at the time of rolling up the prepreg peel ply and the prepreg.
  • FIGS. 1 to 4 are explanatory views showing a basic molding method of the present invention.
  • FIG. 1 is an explanatory view showing a sectional structure of a molding material to be prepared for a method for continuously molding a composite material having stepwise sectional thickness according to the present invention.
  • a molding material whose entire figure is shown by numeral 10 is prepared by laminating three plies of prepreg 31, 32, 33 on each face of a prepreg laminate 20 containing a carbon fibre or the like so that a thickness of the laminate is partially varied by a total of six plies of the prepreg on both faces.
  • three layers of the prepreg whose sectional thickness varies are provided on one face in this figure, the number of layers is not limited to three but may be an arbitrary number.
  • the plies of the prepreg 31, 32, 33 are laminated with the respective ends thereof displaced by one ply. Subsequently, on the laminate 20 of the prepreg, prepreg peel plies 41, 42, 43 are laminated continuously to the ends of the respective plies of the prepreg 31, 32, 33.
  • the prepreg peel ply represented by numeral 40 has a characteristic of being easily peeled from a molding material by a mechanical means even after the composite material having a desired sectional shape was continuously molded by heating and pressurizing of a molding material.
  • FIG. 2 is an explanatory view showing a schema of a sectional structure where a prepreg peel ply 40 and a plurality of layers of prepreg 30 containing the carbon fibre or the like are laminated.
  • the prepreg peel ply 40 is obtained by impregnating a resin 40a into a fabric of a fibre 40b such as polyester, and the fibre is typically has a diameter of approximately fifteen micrometers. Meanwhile, a fibre 30a contained in the prepreg such as a carbon fibre has a diameter of several micrometers. Therefore, even if the resins impregnated respectively in the prepreg peel ply and the prepreg are the same, a fibre diameter and fibre flexibility are different therebetween, thereby facilitating peeling and removal of the prepreg peel ply after curing of the laminated structure.
  • the prepreg peel ply used in the present invention is obtained by impregnating a resin having the same or similar curing properties, especially the same or similar gelation properties, as or to that of prepreg as a member into, for example, a plain weave fabric of a fibre such as polyester or nylon.
  • a resin content by volume ratio of the prepreg peel ply is desirably similar to that of the prepreg.
  • prepreg containing a carbon fibre typically has a thickness of the order of 0.1 to 0.35 mm after curing.
  • the thickness of the prepreg peel ply after curing is also selected from this range, or the same resin as that in the prepreg is impregnated into a fibre fabric having an appropriate fibre area weight and it is thus easy to produce a prepreg peel ply having a thickness approximate to that of the prepreg.
  • the end of the prepreg peel ply 40 arranged continuously to each ply of the prepreg 30 may be butted to the end of the prepreg 30, but a space G 1 , comprised in the range of 0.5 to 1 mm is be formed.
  • FIG. 3 shows a step of making protective films 50 sandwich both faces of this molding material 10 and heating and pressurizing the molding material 10 by means of a pair of molds K 1 , to perform a molding process.
  • the molding material 10 has a uniform thickness, uniform pressure is applied by the molds K 1 so that a favorable composite material can be molded.
  • FIG. 4 shows a step of peeling and removing prepreg peel plies 41, 42, 43, 44 from the surface of the molded article. These prepreg peel plies can be easily peeled and removed from the surface of the molded article by use of a tool such as knife N 1 .
  • FIG. 5 schematically shows a structure of a molded article 100 molded in the foregoing process.
  • the molded article 100 It is possible in the molded article 100 to vary stepwise the thickness in a region shown by symbol D 1 by displacing the ends of a total six plies of the prepreg 31, 32, 33 which are laminated on both faces of the laminate 20 of the prepreg as a center of the molded article 100.
  • the foregoing means is used to mold an H-type member having a thickness that varies stepwise in the longitudinal direction, and the H-type member can be divided into halves to obtain a T-type member 300.
  • a structure can be obtained in which a rib 310 having a large thickness T 10 continues to a rib 320 having a small thickness T 11 through a step portion 330.
  • FIG. 7 shows an example of a molding material 15 in which the end positions of three plies of the prepreg 30 are aligned and the three piles are made opposed to the prepreg peel ply 40.
  • the number of layers is not limited to three but may be an arbitrary number.
  • This molding material 15 is continuously molded and the prepreg peel ply 40 is peeled and removed so that a molded article having stepped portions 35 can be obtained.
  • FIGS. 8 and 9 show means of rolling up the molding material 10 on a reel 710.
  • the prepreg peel ply 40 and the prepreg 30 are laminated on a carrier film 60, and then rolled up on the reel 710 while being covered by a separator film 70.
  • FIG. 10 shows means of supplying the prepreg 30 and the prepreg peel ply 40 from a supply reel 600 and then rolling up the prepreg 40 and the prepreg peel ply 40 on the reel 710 side while sliding those on a base 610.
  • FIG. 11 shows a device that performs continuous molding by using prepreg PP and the molding material 10 of the present invention which are sent out from the supply reel.
  • a continuous molding device 700 comprises a plurality of prepreg supply reels 720 and the reel 710 for supplying the molding material 10 of the present invention.
  • the laminate is molded in a preforming mold 730 into an H-type or an L-type, and molded in a heating and pressurizing mold 740.
  • the molded article is heated in a post-curing oven 750 for a set period of time, to complete curing of the thermosetting resin in the prepreg.
  • the continuously molded product is intermittently sent out through use of a fixing cramp 760 and a pulling cramp 770.
  • FIG. 12 is a timing chart showing opening/closing of the mold 740, opening/closing of the fixing cramp 760 and activation of the pulling cramp 770.
  • FIG. 13 shows rollers 711, 712 for rolling up the separator film 70 at the time of sending out the molding material 10 from the reel 710, and a step of laminating the molding material 10 on the outermost layer of the prepreg laminate 20 in which a plurality of layers of the prepreg PP are laminated.
  • FIGS. 14A and 14B show that the molded article continuously molded by the foregoing means is cut at suitable places C 10 , C 11 , C 12 and the prepreg peel ply 40 is peeled and removed so that products S 1 , S 2 can be obtained which have different thickness stepwise in the longitudinal direction.
  • FIG. 15 shows an H-type member 400.
  • the H-type member 400 has a structure in which parallel flanges 410 are connected with each other through a web 420.
  • the thickness of the portion of the web 420 which is connected with the flange 410 is increased so as to improve rigidity of the H-type member 400.
  • This member has an advantage of increasing its weight only to an extremely small extent.
  • a molding material 10a is rolled up on the reel 710 in a state where the prepreg 30 and the prepreg peel ply 40 are aligned in the width direction on the carrier film 60, and then supplied so that the H-type member 400 of FIG. 16 can be molded.
  • the surface of a prepreg molded article can be covered by laminating glass-fibre containing prepreg thereon according to the intended use.
  • a prepreg peel ply having the same or approximate thickness as or to that of prepreg is calculated by the above calculation formula, and prepreg or a prepreg peel ply comprised of a fibre and a resin in appropriate combination may be selected or produced.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Moulding By Coating Moulds (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Reinforced Plastic Materials (AREA)

Claims (5)

  1. Procédé de moulage en continu d'un matériau composite pré-imprégné ayant une épaisseur de section étagée dans lequel le matériau composite pré-imprégné obtenu par imprégnation de fibres de carbone (30a) ou similaires avec une résine thermodurcissable (40a) est amené par intermittence dans le sens longitudinal et passé ensuite à travers un moule (730, 740) et un four de traitement ultérieur (750), le procédé comprenant les étapes consistant à :
    préparer un matériau de moulage (10) obtenu en superposant, sur un film porteur (60), le matériau composite pré-imprégné (30) et une couche exfoliante de pré-imprégné (40) qui est disposée de façon continue sur le matériau composite pré-imprégné (30) de telle manière qu'un espace (G1), compris dans une plage allant de 0,5 à 1 mm, soit formé entre le matériau composite pré-imprégné (30) et chaque extrémité de la couche de exfoliante de pré-imprégné (40);
    amener le matériau de moulage (10) sur la surface d'un stratifié fait à partir d'un matériau composite pré-imprégné multi-couches (20), lequel est ensuite fait passer à travers un moule (730, 740) et un four de traitement ultérieur (750) ; et à
    peler et enlever la couche exfoliante du pré-imprégné (40) de la surface du stratifié moulé (100, 200, 300, 400).
  2. Procédé de moulage en continu d'un matériau composite pré-imprégné ayant une épaisseur de section étagée selon la revendication 1, dans lequel la couche exfoliante du pré-imprégné (40) a une épaisseur sensiblement égale à celle du matériau composite pré-imprégné (30).
  3. Procédé de moulage en continu d'un matériau composite pré-imprégné ayant une épaisseur de section étagée selon la revendication 1, dans lequel la couche exfoliante du pré-imprégné (40) contient sensiblement la même résine que celle du matériau composite pré-imprégné (30).
  4. Procédé de moulage en continu d'un matériau composite pré-imprégné ayant une épaisseur de section étagée selon la revendication 1, dans lequel le matériau composite pré-imprégné (30) et la couche exfoliante du pré-imprégné (40) sont disposés dans le sens longitudinal du matériau de moulage.
  5. Procédé de moulage en continu d'un matériau composite pré-imprégné ayant une épaisseur de section étagée selon la revendication 1, dans lequel le matériau composite pré-imprégné (30) et la couche exfoliante du pré-imprégné (40) sont disposés dans le sens de la largeur du matériau de moulage.
EP07405292A 2007-03-05 2007-10-02 Procédé de moulage continu de matériel composite ayant une épaisseur sélectionnable par paliers Not-in-force EP1967354B1 (fr)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
JP2007054048A JP4908266B2 (ja) 2007-03-05 2007-03-05 段階状の断面厚さを有する複合材の連続成形方法

Publications (2)

Publication Number Publication Date
EP1967354A1 EP1967354A1 (fr) 2008-09-10
EP1967354B1 true EP1967354B1 (fr) 2010-12-08

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US (1) US8052910B2 (fr)
EP (1) EP1967354B1 (fr)
JP (1) JP4908266B2 (fr)
DE (1) DE602007011032D1 (fr)
ES (1) ES2356014T3 (fr)

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Also Published As

Publication number Publication date
EP1967354A1 (fr) 2008-09-10
US8052910B2 (en) 2011-11-08
DE602007011032D1 (de) 2011-01-20
ES2356014T3 (es) 2011-04-04
JP2008213311A (ja) 2008-09-18
JP4908266B2 (ja) 2012-04-04
US20080217806A1 (en) 2008-09-11

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